MITSUBISHI 380 2005 Workshop Manual

DRIVE SHAFT ASSEMBLY
FRONT AXLE26-24
2. Use special tools MB990890, MB990938, and MB990934 to
press the dust seals into the center bearing bracket until
they are flush with each other.
3. Apply repair kit grease to the lip of each dust seal.
.
>>E<<INNER SHAFT <3.8L-RH> INSTALLATION
1. Use special tool MB991172 to hold the center bearing inner
race, and then press-in the inner shaft.
2. Apply repair kit grease to the inner shaft spline, then press fit
it into the PTJ case.
NOTE: When press-fitting the inner shaft into the PTJ case,
apply a thin coat of repair kit grease to the dust seal outer lip
part and the outside edge of the PTJ axial part.
.

DRIVE SHAFT ASSEMBLY
FRONT AXLE26-25
>>F<< PTJ CASE <3.8L> INSTALLATION
The drive shaft joint use special grease. Do not mix old
and new or different types of grease.
After applying the specified grease to the PTJ case, insert the
drive shaft and apply grease again.
Specified grease: Repair kit grease
Amount to use <3.8L>: 220
10 g (7.8 0.3 ounces)
NOTE: The grease in the repair kit should be divided in half for
use, respectively, at the joint and inside the boot.
.
>>G<< PTJ BOOT BAND (SMALL) <3.8L>/PTJ
BOOT BAND (LARGE) <3.8L> INSTALLATION
Set the PTJ boot bands at the specified distance in order to
adjust the amount of air inside the PTJ boot, and then tighten
the PTJ boot band (small), PTJ boot band (large) securely.
Standard value (A): 85
3 mm (3.35 0.12 inches)
INSPECTIONM1261003800163
Check the drive shaft for damage, bending or corrosion.
Check the inner shaft for damage, bending or corrosion.
Check the drive shaft spline part for wear or damage.
Check the inner shaft spline part for wear or damage.
Check the spider assembly for roller rotation, wear or corro-
sion.
Check the groove inside PTJ case for wear or corrosion.
Check the boots for deterioration, damage or cracking.
Check the center bearing for seizure, discoloration or
roughness of rolling surface.
Check the dust cover for damage or deterioration.

DRIVE SHAFT ASSEMBLY
FRONT AXLE26-26
BJ BOOT REPLACEMENTM1261005200394
Required Special Tool:
MB991561:Boot Band Crimping Tool
1. Remove the boot bands (large and small).
NOTE: The boot bands cannot be re-used.
2. Remove the BJ boot.
3. Wrap a plastic tape around the shaft spline, and assemble
the boot band and BJ boot.
4. Align the center groove on the BJ boot small end with the
shaft groove.
5. Turn the adjusting bolt on special tool MB991561 so that the
size of the opening (W) is at the standard value.
Standard value (W): 2.9 mm (0.11 inch)
<If it is larger than 2.9 mm (0.11 inch)> Tighten the
adjusting bolt.
<If it is smaller than 2.9 mm (0.11 inch)> Loosen the
adjusting bolt.
NOTE: The value of W will change by approximately 0.7 mm
(0.03 inch) for each turn of the adjusting bolt.
NOTE: The adjusting bolt should not be turned more than
once.
6. Position the BJ boot band (small) so that there is even
clearance at either end (A and B).

DRIVE SHAFT ASSEMBLY
FRONT AXLE26-27
Secure the drive shaft in an upright position and clamp
part of the boot band to be crimped securely in the jaws
of special tool MB991561.
Crimp the boot band until the special tool touches the
stopper.
7. Use special tool MB991561 to crimp the boot band (small).
8. Check that the crimping amount (C) of the boot band is at
the standard value.
Standard value (D): 2.4
2.8 mm (0.09 0.11 inch)
<If the crimping amount is larger than 2.8 mm (0.11
inch)>
Readjust the value of (W) in step 5 according to the
following formula, and then repeat the operation in
step 7.
W = 5.5 mm (0.22 inch)
D
Example: If D = 2.9 mm (0.11 inch), then W = 2.6 mm
(0.10 inch).
<If the crimping amount is smaller than 2.4 mm (0.09
inch)>
Remove the EBJ boot band, readjust the value of
(W) in step 5 according to the following formula,
and then repeat the operations in steps 6 and 7
using a new EBJ boot band.
W = 5.5 mm (0.22 inch)
D
Example: If D = 2.3 mm (0.09 inch), then W = 3.2
mm (0.13 inch).
9. Check that the boot band is not sticking out past the place
where it has been installed. If the boot band is sticking out,
remove it and then repeat steps 6 to 8, using a new boot
band.
The drive shaft joint uses special grease. Do not mix old
and new or different types of grease.
10.Fill the inside of the boot with the specified amount of the
specified grease.
Specified grease: Repair kit grease
Amount to use <3.8L>: 165
10 g (5.8 0.3 ounces)

DRIVE SHAFT ASSEMBLY
FRONT AXLE26-28
11.Align the center groove on the BJ boot big end with the BJ
case groove.
12.Follow the same procedure as in step 5 to adjust the size of
the opening (W) on special tool so that it is at the standard
value.
Standard value (W): 2.9 mm (0.11 inch)
13.Position the BJ boot band (large) so that there is even
clearance at either end (D and E).
14.Use special tool to crimp the BJ boot band (large) in the
same way as in step 7.
15.Check that the crimping amount (F) of the boot band is at
the standard value.
Standard value (F): 2.4
2.8 mm (0.09 0.11 inch)
<If the crimping amount is larger than 2.8 mm (0.11
inch)>
Readjust the value of (W) in step 12 according to
the following formula, and then repeat the opera-
tion in step 14.
W = 5.8 mm (0.23 inch)
F
Example: If F = 2.9 mm (0.11 inch), then W = 2.9 mm
(0.11 inch).
<If the crimping amount is smaller than 2.4 mm (0.09
inch)>
Remove the EBJ boot band, readjust the value of
(W) in step 12 according to the following formula,
and then repeat the operations in steps 13 and 14
using a new EBJ boot band.
W = 5.8 mm (0.23 inch)
F
Example: If F = 2.3 mm (0.09 inch), then W = 3.5 mm
(0.14 inch).
16.Check that the boot band is not sticking out past the place
where it has been installed. If the boot band is sticking out,
remove it and then repeat steps 13 to 15, using a new boot
band.

SPECIFICATIONS
FRONT AXLE26-29
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONSM1261005400309
GENERAL SPECIFICATIONSM1261000200311
SERVICE SPECIFICATIONSM1261000300426
ITEM SPECIFICATION
Caliper assembly bolt 100
10 Nm (74 7 ft-lb)
Center bearing bracket bolt 41
4 Nm (30 3 ft-lb)
Drive shaft nut 226
29 Nm (167 21 ft-lb)
Dust cover bolt 9.0
2.0 Nm (80 17 in-lb)
Front strut nut 305
25 Nm (225 18 ft-lb)
Front wheel hub bolt 90
10 Nm (67 7 ft-lb)
Self-locking nut (lower arm ball joint connection) 65
6 Nm (48 4 ft-lb)
Self-locking nut (tie rod end connection) 29
4 Nm (21 3 ft-lb)
ITEM SPECIFICATION
Wheel bearing Type Unit ball bearing (Double-row angular contact ball
bearing)
Drive shaft Joint type Outer Birfield joint
Inner Pillow Tripod joint
ITEM STANDARD VALUE LIMIT
Wheel bearing end play mm (in)
0.05 (0.002)
Wheel bearing rotation starting torque N
m (in-lb)1.4 (12)
Setting of PTJ boot length mm
(in)3.8L 85
3 (3.35 0.12)
Opening dimension of the
special tool (MB991561) mm
(in)When the BJ boot band
(small) is crimped2.9 (0.11)
When the BJ boot band
(large) is crimped2.9 (0.11)
Crimped width of the BJ boot band mm (in) 2.4 2.8 (0.09 0.11)

SPECIFICATIONS
FRONT AXLE26-30
LUBRICANTSM1261000400412
ITEM SPECIFIED LUBRICANT QUANTITY
PTJ boot grease Repair kit grease 220
10 g (7.8 0.3 oz)
BJ boot grease Repair kit grease 165
10 g (5.8 0.3 oz)
Dust seal inner grease Repair kit grease 14
20 g (0.5 0.7 oz)
Dust seal outer grease Repair kit grease 8
12 g (0.3 0.4 oz)

27-1
GROUP 27
REAR AXLE
CONTENTS
GENERAL DESCRIPTION. . . . . . . . .27-2
REAR AXLE DIAGNOSIS . . . . . . . . .27-2
INTRODUCTION TO REAR AXLE DIAGNOSIS27-2
REAR AXLE DIAGNOSTIC
TROUBLESHOOTING STRATEGY . . . . . . 27-2
SYMPTOM PROCEDURES . . . . . . . . . . . . 27-3
SPECIAL TOOLS . . . . . . . . . . . . . . . .27-4
ON-VEHICLE SERVICE . . . . . . . . . . .27-4
WHEEL BEARING END PLAY CHECK . . . 27-4
REAR HUB ROTARY-SLIDING RESISTANCE
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-5HUB BOLT REPLACEMENT . . . . . . . . . . . . 27-5
REAR AXLE HUB ASSEMBLY . . . . .27-6
REMOVAL AND INSTALLATION . . . . . . . . 27-6
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 27-7
KNUCKLE . . . . . . . . . . . . . . . . . . . . . .27-8
REMOVAL AND INSTALLATION . . . . . . . . 27-8
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 27-9
SPECIFICATIONS . . . . . . . . . . . . . . .27-10
FASTENER TIGHTENING SPECIFICATIONS27-10
SERVICE SPECIFICATIONS . . . . . . . . . . . 27-10

GENERAL DESCRIPTION
REAR AXLE27-2
GENERAL DESCRIPTIONM1271000100326
The rear axle has the following features:
The wheel bearing incorporates a unit ball bear-
ing (double-row angular contact ball bearing) for
reduced friction.
The rear wheel hub assembly combines the hub,
wheel bearing, and oil seal in a single unit for
fewer parts, better durability, improved assembly
precision, and better structural organization.
ABS rotor for detecting the wheel speeds is
press-fitted to the rear hub.
CONSTRUCTION DIAGRAM
REAR AXLE DIAGNOSIS
INTRODUCTION TO REAR AXLE DIAGNOSISM1271004100254
Noise from the rear axle may be caused by defects in
the components.
REAR AXLE DIAGNOSTIC TROUBLESHOOTING STRATEGYM1271004200273
Use these steps to plan your diagnostic strategy. If
you follow them carefully, you will be sure that you
have exhausted most of the possible ways to find a
rear axle fault.
1. Gather information from the customer.2. Verify that the condition described by the
customer exists.
3. Find the malfunction by following the Symptom
Procedures.
4. Verify malfunction is eliminated.

REAR AXLE DIAGNOSIS
REAR AXLE27-3
SYMPTOM PROCEDURESM1271004400222
INSPECTION PROCEDURE 1: Abnormal Noise
DIAGNOSIS
STEP 1. Check the rear hub assembly installation bolts for
looseness.
Q: Are the rear hub assembly installation bolts loosened?
YES : Tighten the rear hub assembly installation bolts to the
specified torque 73
7 Nm (54 5 ft-lb). Then go to
St e p 4 .
NO : Go to Step 2.
STEP 2. Check the wheel bearing end play.
(1) Remove the caliper assembly, and suspend the caliper
assembly with a wire and remove the brake disc.
(2) Check the bearing&#39;s end play. Place a dial gauge against
the hub surface; then move the hub in the axial direction
and check whether or not there is end play.
Limit: 0.05 mm (0.002 inch)
Q: Is the wheel bearing end play within the limit?
YES : Go to Step 3.
NO : Replace the rear hub assembly, then go to Step 4.
STEP 3. Check the rear hub rotary-sliding resistance.
(1) Remove the caliper assembly, and suspend the caliper
assembly with a wire and remove the brake disc.
(2) Turn the hub a few times to seat the bearing.
(3) Wind a rope around the hub bolt and turn the hub by pulling
at a 90
angle with a spring balance. Measure to determine
whether or not the rotary-sliding resistance of the rear hub
is within the limit value.
Limit: 24 N (5.4 lbs)
Q: Is the rear hub rotary-sliding resistance within the limit?
YES : Go to Step 4.
NO : Replace the rear hub assembly, then go to Step 4 .
STEP 4. Retest the systems.
Q: Are abnormal noises generated?
YES : Return to Step 1.
NO : The procedure is complete.